Land Rover Defender 90 110 Workshop Book 2 Rover

							2.50 LITRE DIESEL ENGINE 112) 
FIT CYLINDER HEAD.OIL FEED FIT HEATER  PLUGS .. 1 .. . .. 1 ... , c ._.,._. -2 .,_. . ... . . .,. . . .> 
1. Connect  the oil feed  pipe,  for lubrication of the 
2. Secure  with the two  banjo  bolts and four join! 
1. Clean  and test the heater  plugs as described in the 
maintenance  Section. Fit the  heater 
plugs and 
tighten  to the  correct  torque. 
Do not over  tighten. 
2. Fit the  leads,  washers  and nuts as illustrated, 
ensuring  that 
cach cable eyelet  is fitted  vertically 
downwards  to prevent  heat from  cylinder  head 
damaging  the cable  insulation. 
rocker 
shaft assembly, 
to thc cylinder  head 
washers. 
FIT  FUEL  LIFT PUMP 
1. If the fuel lift was  separated from the side  cover,  fit 
the  pump  to 
the cover first using  a new  joint  washer 
between  the pump  flange  and rear  cover,  evenly 
tighten  the retaining  nuts. 
2. Place a new  cover  plate joint washer in position 
and 
fit the  cover  and pump  assembly to the cylinder 
block. 
3. Ensure  that the pump  actuating  lever rides on top 
of 
the camshaft. 
4. Secure the cover,  evenly  tightening  the retaining 
bolts. 
FIT  OIL  FILTER  AND ADAPTOR 
1. Using  a new  joint  washer fit thc oil filter  adaptor. 
Ensure  that the retaining  bolts pass through  the 
two  small  round  holes 
in the joint  washer. 
2. Tightcn  the two  retaining  bolts evenly  to the 
correct  torque. 
3. Smear a little clean enginc oil on the  rubber  washer 
of 
thc new  filter,  then screw  the filter  on clockwise 
until 
the rubber  sealing  ring touches  the machined 
Do not  overtighten.  See Maintenance  Operations, 
section 
10. 
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ST762M continued 
87  
						

							la 2.50 LITRE DIESEL ENGINE 
RENEW 011, TEMPERATURE THERMOSTAT 
Used when  an  oil cooler  is fitted. 
1. Remove  the  two bolts and carefully  withdraw  the 
2. Remove the ‘0’ ring. 
3. Withdraw  the thermostat. 
4.  Remove  the washer. 
5. Remove  the spring. 
6. Clean  the adaptor  housing with lint-free cloth. 
7. Fit the spring  and washer. 
8. Fit a new  thermostat  with the pin  uppermost. 
9. Fit  the  extension  housing  using a new ‘0’ ring. 
Ensure 
that the pin  protruding from thc thermostat 
locates 
in the hole in the extension  housing. 
thermostat 
extension  housing. 
10. Secure the housing with the two  bolts  and washers. 
FIT VACUUM  PUMP 
1. Place a new  joint  washer  on  the cylinder  block 
2. Fit the D.P.S. pump control bracket. 
3. Insert  the vacuum  pump drive shaft into the skew 
gear  coupling  ensuring that the shaft  engages 
properly  over the cross pins 
in the  coupling.  The 
hose connection  should  be towards  the front 
of the 
engine. 
4. Secure  the  pump  and  control  bracket to the 
cylinder  block  with  the three  socket headed  screws. 
face. 
5. Connect 
the D.P.S. pump control  rod to the 
control  bracket lever. 
88  
						

							2.50 LITRE DIESEL ENGINE 
FIT THE  FUEL  INJECTORS AND PIPES 
Fit the  injectors 
The  steel  sealing  washer fitted below the injector 
nozzlc is to ensure  that combustion  does not take  place 
around  the  nozzle body and cause 
it to overheat. A 
washer  which has been  used more  than  once, or an 
incorrectly  fitted  washer  may cause  the nozzle  to 
overheat  and result in  that cylinder misfiring. 
1.  Ensure  that the new  washers  are separated  from 
each  other  and are clean. 
2. Use  a length  of thin welding  wire  to guide  one 
washer  only 
into each  port  with the domed  side 
toward the injector 
as illustrated.  Ensure that  only 
12 
one washer  is fitted  to each  port. 
3. Lightly  grcasc the copper  washer  into  position on 
each injector before  fitting to the cylinder  head. 
4. Fit the  injector  and evenly  tighten  the  retaining 
nuts 
to the  correct  torque.  Uneven or 
overtightening of the  injector  nuts could  distort the 
nozzle  and cause  misfiring  when  normal  running 
temperature  is reached. 
Fit the  injector  pipes 
2. Fit the injcctor pipes to the  injectors  and D.P.S. 
pump. Counting  from the front of the  engine 
connect  the pipes  as follows: 
A. To number  1 injector. 
B. To number 2 injector. 
C. To number 3 injector. 
D. To ilurriber 4 injector. 
Do not overtighten the  union nuts. 
FIT THE  STARTER  MOTOR 
1. Fit the starter  motor to the flywheel  housing and 
secure  with: 
a) one stud  and nut 
b) one  single bolt 
c)  one  nut and  bolt. 
Evenly tighten 
to the  correct torque. 
continued 
89  
						

							1121 2.50 LITRE DIESEL ENGINE 
FIT THE AIR INTAKE  AND EXHAUST  MANIFOLDS 
1. Using a new gaskct fit the  manifolds  and secure 
with  the retaining  nuts and clamps.  Evenly tighten 
to the specified  torque ligure. 
2. Connect the breather  hose to the  oil filler  cap. 
U ST 1550 M 
Turbo-charged engines 
3. Fit a new gasket to the cylinder  head. 
4. Fit thc air intake  manifold  and evenly  lighten  the 
bolts 
to the  correct  torque. I L L- L I 
2. Secure  the rear of the  motor  to the  bracket  with 
two bolts and tighten  to the  correct  torque. 
5. Fit the exhaust  manifold  and secure with the four 
socket  headed  bolts and clamps. 
90  
						

							2.50 LITRE DIESEL ENGINE 
ST769M 
FIT ALTERNATOR - 12 VOLT 
1. Fit adjustment link to front  cover. 
2. Assemble  the alternator  to thc engine brxkct with 
the  two  pivot  bolts, 
distancc piece and  washers, 
leaving  the bolts  slack. 
3. Fit thc adjustment link to the  timing  cover and 
attach 
to alternator with adjusting clamp  bolt. 
12 
STl 
Adjust belt tension 
4. Fit the drive  belt and pivot  the alternator  away 
from  the engine,  but 
do not  apply  pressure  to the 
stator 
or slip-ring  end bracket or damage  may 
result.  Tighten 
the clamp  bolt and with thumb 
pressure,  check 
the belt tension  between  the fan 
and  alternator  pulleys which 
should be 7 to 9 mm 
at the  mid-point. 
5. When the tension  is correct  fully tighten  the clamp 
bolts and 
the pivot  nuts and  bolts. . _. I. . . .a.. .. i... ., .,.. 
FIT PO WEK STEERING PUMP 
1. If removed, fit the jockey  pullcy to the  spindle. 
2. Fit the  bracket  and jockey  pulley assembly  to the 
3. Fit the  power  steering  pump to the bracket  and 
4. Secure the plate  to the bracket  with the three  bolts. 
5. Fit the  drive  pulley to the pump with the three 
6. Fit the drive belt. 
engine 
with the three bolts. 
secure  the plate  to 
the pump  with four bolts. 
bolts. 
91  
						

							1 12 1 2.50 LITRE DIESEL ENGINE 
ADJUST POWER STEERING DRIVE BELT 
1. Slacken the jockey  pulley pinch bolt. 
2. Move  the jockey  pulley to the left or right as 
necessary to achieve  a deflection,  by thumb 
pressure, 
of 12 mm at  the  mid-point of the belt  run 
between  the crankshaft  and power  steering  pump 
pulley. 
3. Tighten  the pinch bolt. 
92  
						

							I,. ,!...  , . I) I ::.....:.: ,.ow pitch knock >ow pitch thud ntermittcnt thuds iigh pitch tap .ight tapping #lapping 
DIESEL ENGINE  MECHANICAL  FAULTS 
POSSIBLE CAUSE 
34.  Low oil level in sump 
35. Low oil pressure 
36.  Excessive  bearing clcarance 
37.  Burnt
-out bearings 38. Loose  bearing caps 
39.  Low  coolant level 40. Faulty cooling system 
41. Faulty  thermostat 
42.  Cracked  cylinder head 
43.  Defective lubrication system 
44.  Thin  or diluted 
oil 45.  Low oil level 46. Choked  pump strainer 
47.  Faulty  release valve 
48. Excessive  bearing clearance 40. Oil pressurc  switch unscrviccablc 50. Elcctrical fault 51. Rclicf valve plunger  sticking 
52.  Weak rcliefvalvc spring 
53.  Pump rotors cxcessively worn 
54.  Excessively  worn hearings; main. connecting 
55. Faulty skcw gear  assembly. 4-cylinder engines 
rod. 
big cnd. camshaft, etc.  ~  ~ 
56. Oil pressure 
relief  valve  plunger sticking 
57.  Sticking  valves 
58. Weak valvc  springs 
59.  Tappet  clearance too wide 60. Deterioration of timing belt 
Big
-end  bearing  slack or run 
Main  bearing  slack  or run 
Loose  flywheel  or excessive  crankshaft end
-float 
Worn  gudgeon  pins 
Exccssive valve clcarancc 
Excessive  piston clearance -more apparanl when cold 
CURE 
Replenish as necessary  to high  mark on dipstick 
Worn  bearings. Faulty skew, gcar  assembly. 
&cylinder engine . Renew bearings;  and or crankshaft 
Renew  and investigate reason  for failure 
Tightcn  to correct  torque 
Chcck  for leaks,  check expansion  tank level 
Check  fan  and belt,  pump,  radiator  fins not 
>locked rest  and renew, if necessary 
Renew 
Renew Filter,  Check pump, Clean strainer. 
:heck oil circulation. Renew oil temperature :hermos ta t . 
- 
Drain  and rcfill with correct oil and renew  filter 
Replensih to high  mark on dipstick :lean Rectify 
Rectify 
Renew 
:heck circuit 
Remove  and ascertain cause 
Pencw 3verhaul oil pump 
4sccrtain which  bearings and  rectify lheck skew gear bearing.  Check plug not leakinf )r seals  in 2.5 diesel  engine. Scc engine overhaul 
Xemovc and clean 
Overhaul  cylinder head 
1 
93  
						

							V8 CYLINDER ENGINE 
DISMANTLE AND OVERHAUL 
Remove induction  manifold 
Remove  the  engine from  the  vehicle  and  clean  the 
exterior. 
In the  interests  of safety  and efficient  working 
secure  the engine 
to a recognised  engine  stand. Drain 
and  discard  the sump  oil. 
Special  tools:
- 
Guide bolts - 605351 
Torque  wrench 
- 18G537 
Clutch centralising  tool - 18G79 
Gudgeon pin removerheplacer - Basic tool - 18G1150 
Adaptor remover/replacer- 
gudgeon  pin. - 18G1150E or 605350 
Spring  compressor 
- lSG106A or R0276102 
Valve guide drift exhaust - 600959 
Valve  cutter  handle set 
- MS76 
8.5 Adjustable  pilot -MS150 
Valve seat cutter - MS621 
Distance  piece for valve  guide - R0605774 
Drift  for guide  removal - inlet and exhaust - 
R0274401 
Crankshaft  rear seal sleeve - R01014 
. 
3. Disconnect miscellaneous pipes and hoses  from the 
induction manifold  and the carburetters. 
4.  Evenly slacken  and remove  the 
twclve bolts and lift 
off  the  induction  manifold  complete with 
carburetters. 
5. Wipe  away any surplus  coolant  lying on the 
manifold gasket  and remove the  gasket clamp  bolts 
and  remove the clamps. 
6. Lift off  the manifold  gasket and  seals. 
REMOVE  ANCILLARY  EQUIPMENT 
Before  commencing,  and whilst  dismantling,  make  a 
careful  note of the  position 
of brackets,  clips harnesses, 
pipes,  hoses filters  and other  miscellaneous  and 
non- 
standard items to facilitate reassembly. 
Remove water pump 
1. Remove  the following  itemsof equipment: 7. Remove the fifteen bolts and  withdraw  the water 
pump  and joint  washer. 
Starter  motor. 
Alternator  and mounting bracket. 
Power 
stecring pump - whcre fitted. 
Disconnect  spark plug 
H.T. leads and remove  the 
distributor. 
Clutch. 
Fan  blades,  pulley and drive belt. 
Remove  pulse air rails  from  cylinder  heads. 
Dipstick  and 
engine mounting  brackets. 
Kemove  exhaust manifolds 
2. Bend back the lock tabs,  and remove  the eight 
bolts  securing  each manifold,  and  withdraw  the 
manifolds. 
94  
						

							V8 CYLINDER ENGINE 
I’ . ., REMOVE AND OVERHAUL  ROCKER SHAFTS AND 
VALVE  GEAR . .1 .* 
1. Remove the four screws  and  lift off  the  rocker 
2. Remove  the  four rocker  shaft rctaining bolts and 
covers 
lift off the assembly 
complete  with  baffle  plate. 
3. Withdraw the pushrods  and  retain in the sequence 
removed. Sl 
Dismantle  rocker shafts 
5. Remove the split  pin  from one end of the  rocker 
4. Withdraw  the following  components  and  retain 
7. A plain washcr. 
8. A wave  washer. 
9. Rocker  arms. 
shaft. 
them 
in the  correct  sequence  for reassembly: 
10. Brackets. 
11. Springs. 
12. Examine  each component  for  wear, in particular 
the  rockers  and shafts.  Discard  weak 
or broken 
springs. 
4. Remove the  hydraulic tappets and place to one side 
with their  respective  pushrods. If a tappet  cannot 
be  removed  leave 
in position  until the camshaft  is 
removed. Inspect  tappets and pushrods 
13. Hydraulic  tappet; inspect inner  and  outer surfaces 
of  body  for  blow holes  and scoring.  Replace 
hydraulic  tappet 
if body is roughly  scored or 
grooved, or has  a blow  hole extending  through the 
wall 
in a  position  to permit  oil leakage  from  lower 
chamber. 
14. The  prominent  wear pattern  just above  lower end 
of body  should not be considered  a defect  unless it 
is definitely grooved or scored. It is caused  by side 
thrust 
of the cam  against thc body  while  the tappet 
is  moving vertically 
in its  guide. 
15. Inspect  the cam contact surface of the tappets.  Fit 
new  tappets 
if the  surface  is exccssively worn or 
damaged. 
16. A hydraulic tappet body that has been  rotating will 
have  a round  wear pattern  and a non-rotating 
tappet  body 
will have a square  wear  pattern with a 
very slight  depression  near the centre. 
17. Tappets  MUST rotate and a circular  wear 
condition  is 
normai. Tappets wiih ihis wear paiierri 
can be refitted  provided thcre are  no other  defects. 
18. In the case of a non-rotating  tappet, fit it new 
replacement  and  check  camshaft  lobes 
for wear; 
also ensure the new  tappet  rotates freely in the 
cylinder  block. 
con1 inued 
95  
						

							1121 V8 CYLINDER ENGINE 
RR750M 
19. Fit a new  hydraulic  tappet if the area  where  the 
pushrod  contacts is rough 
or otherwise  damaged. 
20.  Renew  any pushrod  having a rough 
or damaged 
ball  end 
or seat. Also bent  rods must  be renewed. 
Assemble  rocker shafts 
21. Fit a split pin to one end of the rocker  shaft. 
22.  Slide  a plain  washer  over the long  end of the  shaft 
23.  Fit a wave  washer  to abut  the plain  washer. 
to abut the split  pin. 
25. Compress  the springs,  brackets  and rockers,  and fit 0 
a wave  washer,  plain washer and split pin to the 
end of the rocker  shaft. 
26. Locate  the oil baffle platc in place  over the rockers 
furthest  from the notched  end 
of thc rocker shaft 
and 
fit the  bolts  through  the brackets  and place  the 
assemblies  to one  side. 
REMOVE  AND OVERHAUL THE CYLINDER 
HEADS 
1. Evenly  slacken  the fourteen  cylinder head bolts 
reversing  the tightening  order. 
2. Before removing  the heads  mark them relative  to 
the 
L.H. and R.H. side  of the  engine. 
3. Lift  off the  cvlinder  heads and discard  the gasket. 
NOTE: Two different  rocker arms are used  and 
must  be fitted 
so that  the valve  ends of the  arms 
slope  away from the brackets,  as indicated  by the 
dotted  lines 
A on the illustration.  Dismantle 
cylinder heads -- E r. -_ -/ 24. Assemble  the rocker  arms, brackets  and springs to 4. Remove  the spark  plugs. 5. Using  the valve  spring  compressor  276102, or a 
suitable alternative,  remove the valves  and springs 
the 
rocker  shaft. 
and retain  in sequence 
for refitting. 
/ , , I 
ST788M 
i .7 
96